Pile fabric and method of weaving



May 10, 1960 T. T. JANNEY 2,936,004

PILE FABRIC AND METHOD OF WEAVING Filed March 14, 1957 F JC c e 5 s 4; BT51 5 5 15 INVENTOR'.

THOMAS T. JA NNEY ATTV L i r i construction does have, however, some disadvantage 7 Claims. (c1. tee-404 This invention relates to an improved pile fabric andw more particularly to a Wilton-type carpet having superior wear and strength features.

In order to achieve better stability in the ground fabric of a floor covering and at the same time to conserve the amount of face yarn used, it is desirable to weave some of the face yarn through to the back in a multi-shot Wiltontype fabric. Where a conventional two-shot construction is used having upper and lower planes of filling shots bound together by chain warps and a plurality of stuffer warps carried between the shots, it is well known to weave the face yarn under some or all of the upper shots. This from a quality standpoint in that the pile material is not bound as firmly as in other constructions and, also, the weight and stiffness of the ground fabric is not all that might be desired. However, in carrying all or substantially all of the face yarn through to the back or running dead along with the stuffer, there is a very substantial increase in cost because of the amount of relatively expensive yarn that is used. v

Contrary to conventional practice, I weave the ground fabric of the present invention with two succeeding filling shots over the stuffer and the next succeeding two filling shots under the stutter or vice versa. The stutfers are tensioned sufficiently so that they are relatively straight in the ground fabric, whereas each filling weft is woven under and over the stutter and pile warps. In the preferred form, a single chain warp is shown since this suflices to anchor the filling and the stuifer. The pile warps may be carried over a plurality of wefts and pile wires, through to the back between the wire and a weft, or they may run dead with the stutter warps.

A primary object of the invention then is to provide a two-shot, Wilton-type fabric in which. each weft shot passes above and below the stufler warps.

A further object of the invention is to provide a Wiltontype fabric in which the weft shots pass in pairs above and below the stutter warps.

A further object of the invention is to provide in a twoshot, Wilton-type fabric having a pair of adjacent weft shots on the same side of the stutter, pile warps carried through to the back under single bottom shots of pairs, tied in under single top shots of pairs, tied in under a single bottom shot, over the next bottom shot, under the next top shot and the succeeding top shot.

A still further object is to provide in a fabric of the type described, a pile yarn carried through to the back and tied in under a single bottom shot, then over the next bottom shot and under its associated pile wire, then over the next pile wire.

Further objects will be apparent from the specification and drawings in which Fig. l is a top view diagrammatically illustrating a fabric of the present invention,

Fig. 2 is a section as seen at 2-2 of Fig. 1,

Fig. 3 is a section as seen at 33 of Fig. 1,

Fig. 4 is a section as seen at 4-4 of Fig. 1, and

Figs. 5-7 show various draws used to produce fabrics of the invention.

2,936,004 Patented May 10, 1960 "ice present fabric in its preferred form has pairs of weft 011;

filling shots 10a, 10b, 11a, 111), etc., through 17a, 17b.

The filling shots interweave with the stuifer wa-rpsbut the individual shots are preferably separated by pile yarns. Stuifer warps 20, 20 are interwoven with pairs of shots 10-17. Chain warps 21, 21 pass successively under and over pairs of shots. Contrary to usual practice, the terminology top and bottom shots cannot be strictly applied to the various filling wefts because each weft weaves from top to bottom, so that in Fig. 2 certain pairs of wefts appear as bottom shots whereas the same wefts appear as top shots in Fig. 3. The position of the shots in the sectional views is clearly designated in the tables hereinafter. Preferably I utilize two pile warps 22 and 23 in;

i1 each dent and these warps may be individually or jointly carried over, under, and between individual as well as pairs of weft shots in a manner which provides novel eifects.

The weave diagrams of Figs. 24 show diagrammatically sections of the fabric before the pile wires 2532 have been withdrawn. Thesewires may be any selectedcombinationof high and low round wires, profile wires, and cutting wires. The following tables may be used to trace the relative relation of the two pile warps in dents A and and Figs. 2 and 3.

B as seen in Fig. 1

- Dent A (Fig. 2)

Yarn 22 Shot Position of Yarn 23 Shot 1011"-.- Top Under....Q Under. 1012"-.. o. Over shot and wire 25.-. Oger shot, under wire 0. 11a"-.. Bottom..- Under Under. 11b ...do Over shot and wire 26.-. 0x27? shot, under wire 12a Top High float Under. 12b do Over shot and wire 27..- Oger shot, under wire Under Under. Over shot, under wire 28. Over shot and Wire 28. Intermediate float Under. Over shot and wire 29. Over shot, under Wire Under Under. Over shot and wire 30. Oggr shot, under wire Under Under. Over shot and Wire 31 Ova er shot, under wire 1. Under Under. Over shot and wire 32-.. ogtzer shot, under wire Dent B (Fig. 3)

Shot Position of Yarn 22 Yarn 23 Shot Under Under. Over shot, under wire 25 Over shot and wire 25.

n er Under. Over shot and wire 26.-. Over shot and wire 26. Under High float. Over shot and wire Over shot and wire 27. Intermediate float" d Un er.

Over shot; under wire 28. Over shot and wire 28.

nder nder.

Over shot and wire 29..- Ovgr shot, under wire Underz. Under. Over shot, under Wire 30. Over shot and wire 30.

nder Under. (1 Over shot, under wire 31- Over shot and wire 31.

17a Top n or Under. 17b. do Over shot and wire 32.-- Over shot and wire 32.

design I This weaving provides a very unusual and interesting combination of loops and ground pile fabric which has a definite ground coverage and selective high and intershown in Fig. 2 under weft shot 13a, thence over the next shot13b, under the associated wire 28, and directly over the next wire 29.

Another variation of an intermediate float is shown at I, Fig. 3, in which'pile yarn 22 is carried over wire 27, over shot 13a, over shot 13b, under wire 28, and then through to the back to be tied in under shot 14a. The inherent nature of the weave of the present invention illustrates the difference between the intermediate floats H and I, because in float H the yarn 22 is carried over wire 29 which is associated with shot 14b in top position, and the float H is tied in under shot 13a in bottom position. Furthermore, the float passes over shot 14a in top position and shot 13b in bottom position. Compare this with float J in which the wire 27 forming the float is associated'with shot 12b in bottom position and the float is carried to the first next succeeding bottom weft 14a rather than the second one 1411.

The draw for the fabric shown in Figs. 1-4 is shown schematically in Fig. 5, in which the chain for dent C is controlled by harness 35, the stuifer for dent C and the chain for dent D, which is adjacent to it, are controlled by harness 36 and stuffer for dent C is carried through harness 35. The repeat is indicated at 37. It will thus be apparent that the chains and the staffers in adjacent dents work oppositely.

Fig. 6 illustrates the same basic draw but with a longer repeat 39. In this variation the draw in dents E and F is identical, with the chains on harness 35 and the stuffer for each dent on harness 36. However, the draw for dents G and H is the reverse with the stuifers on harness 35 and the chains on harness 36. A narrower repeat 40 is shown in Fig. 7 in which all the stuifers work in harness 35 and all the chains in harness 36 so that when the stuffer warps are up all chain warps are down and the cross section of each dent would be the same.

It is, therefore, possible to provide different types of intermediate floats in the same weave depending upon which position of the particular weft shot is selected to tie under and whether the wire forming the float is assotom position. Similarly, individual variations in all the other formations are possible, thus creating an extremely wide range of texture effects available to the designer.

Having thus described my, invention, I claim:

1. A Wilton type pile fabric having stutfer warps, a plurality of weft shots interwoven with said suffer warps, a'chain warp binding the weft shots, a plurality of pile warps tied under weft shots both above and below the staffer warps, the same weft shots binding down pile yarns on the top and on the bottom of the fabric.

2. A fabric in accordance with claim 1 in which the weft shots interweave in pairs with the stuffer warps.

3. A fabric in accordance with claim 1 in which pairs of stuffer warps interweave with pairs of weft shots.

4. A fabric in accordance with claim 1 in which the pile warps interweave in pairs with the weft shots.

5. A pile carpet fabric having pairs of relatively straight stulfer warps, pairs of weft shots interweaving with said stuffer warps which pass alternately over the top and under the bottom of the stulfer warps, chain warps for binding the weft shots a pile yarn between pairs of stuffer warps said. pile yarn tied down under one weft shot on the bottom of the fabric and under another weft shot on the top of the stutfer warp and passing over at least one intermediate weft shot.

6. In the manufacture of pile fabrics having pile warps, stuffer warps, chain warps, and filling wefts, the method which comprises the steps of interweaving pairs of filling wefts and stulfer warps, weaving selected pile warps over at least two pile wires and associated filling wefts, and tying in said pile warps under a single weft shot of a pair on the bottom of the fabric.

7. In the manufacture of pile fabrics having pile warps, stuifer warps, chain warps, and filling wefts, the method which comprises the steps of interweaving pairs of filling wefts with stufier warps, weaving selected pile warps between single wefts of pairs of weft shots, and under an associated pile wire.

References Cited in the file of this patent UNITED STATES PATENTS Great Britain of 1912 

